IEC 62485-3:2010
(Main)Safety requirements for secondary batteries and battery installations - Part 3: Traction batteries
Safety requirements for secondary batteries and battery installations - Part 3: Traction batteries
IEC 62485-3:2010 applies to secondary batteries and battery installations used for electric vehicles, e.g. in electric industrial trucks (including lift trucks, tow trucks, cleaning machines, automatic guided vehicles), in battery powered locomotives, in electric vehicles (e.g. goods vehicles, golf carts, bicycles, wheelchairs), and does not cover the design of such vehicles. This International Standard covers lead dioxide-lead (lead-acid), nickel oxide-cadmium, nickel-oxide-metal hydride and other alkaline secondary batteries. Safety aspects of secondary lithium batteries in such applications will be covered in their own appropriate standards. The nominal voltages are limited to 1 000 V AC and 1 500 V DC respectively and describe the principal measures for protection against hazards generally from electricity, gas emission and electrolyte. It provides requirements on safety aspects associated with the installation, use, inspection, maintenance and disposal of batteries.
Exigences de sécurité pour les batteries d'accumulateurs et les installations de batteries - Partie 3: Batteries de traction
La CEI 62485-3:2010 s'applique aux installations d'éléments et de batteries d'accumulateurs utilisées pour les véhicules électriques par exemple dans les chariots électriques industriels (y compris chariots élévateurs, tracteurs, machines de nettoyage, véhicules automatiques guidés), locomotives alimentées par batteries, véhicules électriques routiers (par exemple véhicules pour le transport de marchandises, voiturettes de golf, bicyclettes, chaises roulantes), et ne couvre pas la conception de tels véhicules. Cette norme internationale couvre les accumulateurs au plomb/dioxyde de plomb (plomb acide), oxyde de nickel/cadmium, oxyde de nickel/hydrure métallique et autres accumulateurs alcalins. Les aspects de sécurité des accumulateurs lithium dans ces applications seront couverts par les normes qui leur sont propres. Les tensions nominales sont limitées respectivement à 1 000 V en courant alternatif et 1 500 V en courant continu et donnent les principales mesures de protection contre les risques produits en général par l'électricité, les émissions de gaz et l'électrolyte. Elle fournit les exigences concernant les aspects de sécurité liés à la mise en oeuvre, à l'utilisation, au contrôle, à la maintenance et à la mise au rebut des batteries.
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IEC 62485-3 ®
Edition 1.0 2010-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety requirements for secondary batteries and battery installations –
Part 3: Traction batteries
Exigences de sécurité pour les batteries d’accumulateurs et les installations
de batteries –
Partie 3: Batteries de traction
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IEC 62485-3 ®
Edition 1.0 2010-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety requirements for secondary batteries and battery installations –
Part 3: Traction batteries
Exigences de sécurité pour les batteries d’accumulateurs et les installations
de batteries –
Partie 3: Batteries de traction
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
S
CODE PRIX
ICS 29.220.20; 29.220.30; 43.040.10 ISBN 978-2-88910-997-5
– 2 – 62485-3 © IEC:2010
CONTENTS
FOREWORD.4
1 Scope.6
2 Normative references.6
3 Terms and definitions .6
4 Protection against electric shock by the battery and charger.8
4.1 General .8
4.2 Protection against both direct and indirect contact.9
4.3 Protection against direct and indirect contact when discharging the traction
battery on the vehicle (battery disconnected from charger/mains).9
4.4 Protection against direct and indirect contact when charging the traction
battery.10
5 Prevention of short circuits and protection from other effects of electric current .10
5.1 Cables and cell connectors .10
5.2 Protective measures during maintenance.10
5.3 Battery insulation .11
5.3.1 General .11
6 Provisions against explosion hazards by ventilation.11
6.1 Gas generation.11
6.2 Ventilation requirements .12
6.2.1 General .12
6.2.2 Standard formula .12
6.2.3 Special formula.13
6.2.4 Unconventional chargers.14
6.2.5 Multiple charging.14
6.3 Natural ventilation.14
6.4 Forced ventilation .15
6.5 Close vicinity to the battery .15
6.6 Ventilation of battery compartment.15
7 Provisions against electrolyte hazard .15
7.1 Electrolyte and water .15
7.2 Protective clothing .15
7.3 Accidental contact, "first aid".15
7.3.1 General .15
7.3.2 Eye contact.16
7.3.3 Skin contact.16
7.4 Battery accessories and maintenance tools.16
8 Battery containers and enclosures .16
9 Accommodation for charging/maintenance .16
10 Battery peripheral equipment/accessories .17
10.1 Battery monitoring system.17
10.2 Central water filling system .17
10.2.1 General .17
10.2.2 Safety aspects .18
10.3 Central degassing systems .18
10.4 Thermal management systems .18
10.5 Electrolyte agitation system .18
10.6 Catalyst vent plugs .19
62485-3 © IEC:2010 – 3 –
10.7 Connectors (plugs/sockets).19
11 Identification labels, warning notices and instructions for use, installation and
maintenance.19
11.1 Warning labels .19
11.2 Identification label.19
11.3 Instructions.20
11.4 Other labels.20
12 Transportation, storage, disposal and environmental aspects .20
12.1 Packing and transport.20
12.2 Disassembly, disposal, and recycling of batteries .20
13 Inspection and monitoring .20
Bibliography .22
Table 1 – Gas producing current I respectively typical end of charge current in A per
gas
100 Ah rated capacity, when charging with IU or IUI-chargers.13
– 4 – 62485-3 © IEC:2010
INTERNATIONAL ELECTROTECHNICAL COMMISSION
_____________
SAFETY REQUIREMENTS FOR SECONDARY BATTERIES
AND BATTERY INSTALLATIONS –
Part 3: Traction batteries
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
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6) All users should ensure that they have the latest edition of this publication.
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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62485-3 has been prepared by IEC technical committee 21:
Secondary cells and batteries.
The text of this standard is based on the following documents:
FDIS Report on voting
21/712/FDIS 21/719/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts of the IEC 62485 series can be found, under the general title Safety
requirements for secondary batteries and battery installations, on the IEC website.
62485-3 © IEC:2010 – 5 –
The committee has decided that the contents of this publication will remain unchanged until the
stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data related to
the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – 62485-3 © IEC:2010
SAFETY REQUIREMENTS FOR SECONDARY BATTERIES
AND BATTERY INSTALLATIONS –
Part 3: Traction batteries
1 Scope
This part of the IEC 62485 applies to secondary batteries and battery installations used for
electric vehicles, e.g. in electric industrial trucks (including lift trucks, tow trucks, cleaning
machines, automatic guided vehicles), in battery powered locomotives, in electric vehicles (e.g.
goods vehicles, golf carts, bicycles, wheelchairs), and does not cover the design of such
vehicles.
This International Standard covers lead dioxide-lead (lead-acid), nickel oxide-cadmium, nickel-
oxide-metal hydride and other alkaline secondary batteries. Safety aspects of secondary lithium
batteries in such applications will be covered in their own appropriate standards.
The nominal voltages are limited to 1 000 V AC and 1 500 V DC respectively and describe the
principal measures for protection against hazards generally from electricity, gas emission and
electrolyte.
It provides requirements on safety aspects associated with the installation, use, inspection,
maintenance and disposal of batteries.
2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.
IEC 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock
IEC 60900, Live working – Hand tools for use up to 1 000 V a.c. and 1 500 V d.c.
IEC 61140, Protection against electric shock – Common aspects for installation and equipment
ISO 3864 (all parts), Graphical symbols – Safety colours and safety signs
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
(secondary) cell
(rechargeable) cell
single cell
assembly of electrodes and electrolyte which constitutes the basic unit of a secondary battery
62485-3 © IEC:2010 – 7 –
NOTE This assembly is contained in an individual case and closed by a cover.
3.2
lead dioxide-lead (acid) battery
secondary battery with an aqueous electrolyte based on dilute sulphuric acid, a positive
electrode of lead dioxide and a negative electrode of lead
3.3
nickel oxide-cadmium battery
secondary battery with an alkaline electrolyte, a positive electrode containing nickel oxide and
a negative electrode of cadmium
3.4
vented (secondary) cell
a secondary cell having a cover provided with an opening through which gaseous products may
escape
3.5
valve regulated (secondary) cell
secondary cell which is closed under normal conditions but has an arrangement which allows
the escape of gas if the internal pressure exceeds a predetermined value. The cell cannot
normally receive addition to the electrolyte
3.6
gas-tight sealed (secondary) cell
secondary cell which remains closed and does not release either gas or liquid when operated
within the limits of charge and temperature specified by the manufacturer. The cell may be
equipped with a safety device to prevent dangerously high internal pressure
NOTE The cell does not require addition to the electrolyte and is designed to operate during its life in its original
sealed state.
3.7
secondary battery
two or more secondary cells connected together and used as a source of electrical energy
3.8
traction battery
secondary battery which is designed to provide the propulsion energy for electric vehicles
3.9
monobloc battery
battery with multiple separate but electrically connected cell compartments each of which is
designed to house an assembly of electrodes, electrolyte, terminals and interconnections and
possible separator
NOTE The cells in a monobloc battery can be connected in series or parallel.
3.10
electrolyte
liquid or solid substance containing mobile ions which render it ionically conductive
NOTE The electrolyte may be a liquid, solid or a gel.
3.11
gassing
gas emission
evolution of gas resulting from the electrolysis of water in the electrolyte of the cell
– 8 – 62485-3 © IEC:2010
3.12
charge
charging (of a battery)
operation during which a secondary cell or battery is supplied with electrical energy from an
external circuit which results in chemical changes within a cell and thus storage of energy as
chemical energy occurs
3.13
equalisation charge
extended charge which ensures complete charging of all cells in a battery
3.14
opportunity charging
use of free time during a work period to top up the charge and thus extend the work period of a
battery whilst avoiding excessive discharge
3.15
overcharge
overcharging (of a cell or battery)
continued charging after the full charge of a cell or battery
NOTE Overcharge is also the act of charging beyond a certain limit specified by the manufacturer.
3.16
discharge
discharging (of a battery)
operation during which a battery delivers, to an external circuit and under specified conditions,
electrical energy produced in the cells
3.17
(battery) peripheral equipment
equipment installed on the battery, which supports or monitors the operation of the battery, e.g.
central water filling system, electrolyte agitation system, battery monitoring system, central de-
gassing system, battery connectors (plugs and sockets), thermal management system, etc
3.18
charging room
room or closed area intended specifically for recharging batteries. The room may also be used
for battery maintenance
3.19
charging area
open area designated and made suitable for recharging batteries. The area may also be used
for battery maintenance
4 Protection against electric shock by the battery and charger
4.1 General
Measures shall be taken on traction batteries and in traction battery charging installations for
protection against either direct contact or indirect contact, or against both direct and indirect
contact.
These measures are described in detail in IEC 60364-4-41 and IEC 61140. The following
clauses and the resulting amendments describe the typical measures to be taken for traction
battery installations.
62485-3 © IEC:2010 – 9 –
The appropriate equipment standard IEC 61140 applies to batteries and direct current
distribution circuits located inside equipment.
4.2 Protection against both direct and indirect contact
On batteries and in battery charging installations protection against direct contact with live
parts shall be ensured in accordance with IEC 60364-4-41.
The following protective measures against direct contact apply:
– “protection by insulation of live parts”;
– “protection by barriers or enclosures”;
– “protection by obstacles”;
– “protection by placing out of reach”.
The following protective measures against indirect contact apply:
– “protection by automatic disconnection or signalling”;
– “protection by protective insulation”;
– “protection by earth-free local equipotential bonding”;
– “protection by electrical separation”.
4.3 Protection against direct and indirect contact when discharging the traction
battery on the vehicle (battery disconnected from charger/mains)
4.3.1 For batteries having a nominal voltage up to and including 60 V DC, protection against
electric shock caused by direct contact is not formally required, as long as the whole
installation corresponds to the conditions for safety extra low voltage (SELV) and protective
extra low voltage (PELV).
NOTE The nominal voltage of a lead dioxide - lead cell (lead acid) is 2,0 V, that of a nickel oxide – cadmium or
nickel oxide - metal hydride cell is 1,2 V. When these cells are boost charged, their voltage may reach 2,7 V in lead
acid or 1,6 V in nickel oxide based systems.
However, for other reasons, e.g. short circuits, mechanical damage etc., all batteries in
electrical vehicles shall be protected against direct contact of live parts, even if the battery
nominal voltage is 60 V DC or less.
4.3.2 For batteries having a nominal voltage above 60 V DC and up to and including 120 V DC,
protection against electric shock caused by direct contact is required.
NOTE Batteries with nominal voltage up to and including 120 V DC are regarded as safe power sources for SELV-
systems (safety extra low voltage) or PELV-systems (protective extra low voltage), see IEC 60364-4-41,411.1.
The following protective measures apply:
– “protection by insulation of live parts”;
– “protection by barriers or enclosures”;
– “protection by obstacles”;
– “protection by placing out of reach”.
If the protection against direct contact of live parts is ensured only by obstacles or placing out
of reach, access to the battery accommodation shall be restricted to trained and authorized
personnel only, and the battery accommodation shall be marked by appropriate warning labels
(see Clause 11).
For batteries having a nominal voltage exceeding 120 V DC, protective measures against both
direct and indirect contact are required.
– 10 – 62485-3 © IEC:2010
Battery compartments with batteries having a nominal voltage exceeding 120 V DC shall be
locked and have restricted access for trained and authorized personnel only and shall be
marked by appropriate warning labels (see Clause 11).
For batteries with a nominal voltage exceeding 120 V DC, the following protective measures
against indirect contact apply:
– “protection by electrical insulation of live parts”;
– “protection by earth-free equipotential local bonding”;
– “protection by automatic disconnection or signalling”.
4.4 Protection against direct and indirect contact when charging the traction battery
When battery chargers with safe galvanic separation from the feeding mains are used
according to IEC 61140, the protective measures SELV or PELV shall be applied. If the
nominal voltage of the battery does not exceed 60 V DC protection against direct contact is not
formally required, as long as the total installation corresponds to conditions of SELV or PELV.
When the battery charger does not comply with these requirements, then the protective
measures against direct and indirect contact shall be applied according to IEC 60364-4-41.
However, for other reasons, e.g. short circuits, mechanical damage etc., all batteries in
electrical vehicles shall be protected against direct contact of live parts, even if the battery
nominal voltage is 60 V DC or less.
5 Prevention of short circuits and protection from other effects of electric
current
5.1 Cables and cell connectors
Cables and cell connectors shall be insulated to prevent short circuits.
If protection against short circuits cannot be provided by over-current protection devices for
battery-specific reasons, then the connecting cables between charger, respective battery fuse,
and battery, and between battery and vehicle shall be protected against short circuits and earth
fault.
The cables shall meet the requirements of IEC 60204-1.
When a trailing cable is used, the protection against short circuits shall be improved by the use
of single core cable according to IEC 60204-1. However, where the battery nominal voltage is
less than or equal to 120 V DC, a trailing cable of grade H01ND2, for higher flexibility, can be
used.
The battery terminal cables shall be fixed in a manner that prevents tensile and torsional strain
on the battery terminals.
Insulation shall be resistant to the effects of ambient influences such as temperature,
electrolyte, water, dust, commonly occurring chemicals, gasses, steam and mechanical stress.
5.2 Protective measures during maintenance
When working on live equipment, appropriate procedures shall be implemented so to reduce
the risk of injury and only insulated tools according to IEC 60900 shall be used.
To minimize the risk of injury, the following measures shall be implemented:
62485-3 © IEC:2010 – 11 –
– batteries shall not be connected or disconnected before the load or charging current has
been switched off;
– battery terminal and connector covers shall be provided which allow routine maintenance
whilst minimising exposure of energized conductive parts;
– all metallic personal objects shall be removed from the hands, wrists and neck before
starting work;
– for battery systems where the nominal voltage is above 120 V DC, insulated protective
clothing and/or local insulated coverings shall be required to prevent personnel making
contact with the floor or parts bonded to earth.
NOTE It is strongly advisable that batteries, having a nominal voltage above 120 V DC and undergoing
maintenance, are divided into sections consisting of 120 V DC (nominal) or less.
5.3 Battery insulation
5.3.1 General
This clause does not apply to batteries used in electrically propelled road vehicles where the
battery insulation requirement is covered by particular standards for that application.
5.3.2 A new, filled and charged battery shall have an insulation resistance of at least 1 MΩ
when measured between a battery terminal and metallic tray, vehicle frame or other conductive
supporting structure. Where the battery is fitted into more than one container, this requirement
applies with the sections, including metal battery containers, electrically connected.
5.3.3 A battery in use, having a nominal voltage not higher than 120 V DC, shall have an
insulation resistance of at least 50 Ω multiplied by the nominal battery voltage but not less than
1 kΩ when measured between a battery terminal and metallic tray, vehicle frame or other
conductive supporting structure. If the nominal battery voltage exceeds 120 V DC an isolation
resistance of at least 500 Ω multiplied by the nominal battery voltage is required. Where the
battery is fitted into more than one container, this requirement applies with the sections,
including metal battery containers, electrically connected.
5.3.4 The insulation resistance of the vehicle and traction battery shall be checked separately.
The resistance test voltage shall be higher than the nominal voltage of the battery, but no more
than 100 V DC or three times the nominal voltage (see EN 1175-1).
6 Provisions against explosion hazards by ventilation
6.1 Gas generation
During charge processes, gases are emitted from all secondary cells and batteries excluding
gastight (secondary) cells. This is a result of the electrolysis of the water by the overcharging
current. Gases produced are hydrogen and oxygen. When emitted into the surrounding
atmosphere, an explosive mixture may be created if the hydrogen concentration exceeds
4 % hydrogen in air.
vol
In order to avoid detrimental heat development and excessive gassing of the batteries, care
shall be taken to use battery chargers with appropriate size and performance characteristics for
the batteries to be charged.
When gas emission is determined experimentally with battery test standards and the value
found is lower than that used in the present standard, then no de-rating of the ventilation
requirements shall be admissible. If the experimental gas emission value is higher than the
value assumed in the present standard, then the ventilation requirements shall be adapted i.e.
increased.
– 12 – 62485-3 © IEC:2010
When a cell reaches its fully charged state, water electrolysis occurs according to the
Faraday‘s law. Under standard conditions i.e at 0 °C and 1 013 hPA (STP under IUPAC):
− 1 Ah decomposes 0,336 g H O into 0,42 l H + 0,21 l O ;
2 2 2
− 3 Ah decompose 1 cm (1 g) of H O;
.
− 26,8 Ah decompose 9 g H O into 1 g H + 8 g O
2 2 2
When the operation of the charge equipment is stopped, the emission of gas from the cells will
substantially subside within one hour. However, precautions are still necessary after this time,
as gas trapped within the cells can be released suddenly due to movement of the battery when
it is refitted to the vehicle or when the vehicle moves in service.
6.2 Ventilation requirements
6.2.1 General
The ventilation requirements of this subclause shall be met whether the battery is charged on
or off the vehicle.
The purpose of ventilating a battery location or enclosure is to maintain the hydrogen
concentration below the 4 % hydrogen threshold. Battery accommodation rooms are to be
considered as safe from explosions, when by natural or artificial ventilation, the concentration
of hydrogen is kept below this safe limit. The necessary ventilation airflow for a battery location
or compartment shall be calculated by use of one of the two following formulae.
6.2.2 Standard formula
The standard formula shall be used with any type of conventional battery charger when
charging vented or valve-regulated lead-acid batteries or vented nickel-cadmium batteries:
Q = v × q × s × n × I × z [m /h]
gas standard
where
Q is the ventilation air flow in m /h;
(100 % − 4 %)
v is the necessary dilution of hydrogen: = 24 ;
4 %
–3 3
q = 0,42 × 10 m /Ah generated hydrogen at 0 °C;
Remark: for calculations at 25 °C, the value of q at 0 °C shall be multiplied by
factor 1,095;
s = 5, general safety factor;
n is the number of cells;
I = gassing current equal to 30 % of the rated output current of the involved charger
gas standard
[A];
z = 1,0 for vented batteries;
z = 0,25 for valve-regulated batteries de-rating factor due to internal gas
recombination.
The ventilation air flow calculation formula can be resolved into the following:
Q = 0,05 × n × I × z [m /h]
gas standard
NOTE 1 A 48 V vented lead-acid traction battery consisting of 24 cells is to be charged from a charger with output
rating 48 V/ 80 A. According to the above definitions, the value of I = 0,30 × 80 = 24 [A] and the value of
gas standard
z = 1,00.
The ventilation air flow requirement amounts to Q = 0,05 × 24 × 24 × 1,00 = 28,8 [m /h].
62485-3 © IEC:2010 – 13 –
NOTE 2 A 24 V valve-regulated lead-acid wheel-chair battery consisting of 12 cells is to be charged from a
charger with output rating 24 V/10 A. According to the above definitions, the value of I = 0,30 × 10 = 3,0
gas standard
[A] and the value of z = 0,25.
The ventilation air flow requirement amounts to Q = 0,05 × 12 × 3,0 × 0,25 = 0,45 [m /h].
6.2.3 Special formula
Regardless of 6.2.2, the following special formula can be used with conventional chargers with
controlled voltage and current output performance when detailed information on chargers,
charging profiles and battery types are available and ventilation air flow optimization is desired
Q = v × q × s × n × I × C / 100 [m /h]
gas special n
where
Q is the ventilation air flow in m /h;
(100 % − 4 %)
v is the necessary dilution of hydrogen: = 24 ;
4 %
–3 3
q = 0,42 × 10 m /Ah generated hydrogen at 0 °C ;
Remark: for calculations at 25 °C, the value of q at 0 °C shall be multiplied by
factor 1,095;
s = 5, general safety factor;
n is the number of cells;
I = gassing current in A/100 Ah rated battery capacity (C ) per Table 1.
gas standard 5
The ventilation air flow calculation formula can be resolved into the following:
Q = 0,05 × n × I × C / 100 [m /h]
gas special n
For calculation of the required ventilation air flow at least the minimum values of the gassing
current I [A/100 Ah] as per Table 1 shall be used.
gas special
Table 1 – Gas producing current I respectively typical end of charge current in A per
gas
100 Ah rated capacity, when charging with IU or IUI-chargers
Charger Gassing current I in A /100 Ah (minimum values)
gas special
characteristics
Vented lead acid Valve regulated lead Vented nickel Sealed nickel
battery cells acid cells cadmium cells
cadmium or nickel
metal hydride cells
IU charging (2,4 V/cell max.) (2,4 V/cell max) (1,55 V/cell max)
2 1,0 5
Consult manufacturer
rd rd rd
IUI charging Current in 3 charging Current in 3 charging Current in 3 charging
of cells and charger
step but not less than step but not less than step but not less than
5 1,5 5
NOTE 1 A 24 V valve-regulated lead-acid traction battery consisting of 12 cells with a nominal capacity of 256 Ah
is to be charged with an adequate IU-charger with a voltage setting of max 28,8 V. The voltage setting corresponds
to 28,8/12 = 2,40 V/ cell and thus the I value of 1,0 A/100 Ah of Table 1 applies.
gas special
The ventilation air flow requirement amounts to: Q = 0,05 × 12 × 1,0 × 256/100 = 1,54 [m /h].
NOTE 2 A 48 V vented nickel-cadmium battery consisting of 40 cells with a nominal capacity of 180 Ah is to be
rd
charged with an IUI charger having an output current of 6,3 A in the 3 charging step, corresponding to 6,3/180 =
0,035 A/Ah = 3,5 A/100 Ah. This is less than the minimum allowed value of I per Table 1. Therefore at
gas special
– 14 – 62485-3 © IEC:2010
least the minimum I value of 5 A/100 Ah in Table 1 shall be used for the calculation of the ventilation air
gas special
flow
The ventilation air flow requirement amounts to: Q = 0,05 × 40 × 5 × 180/100 = 18,0 [m /h].
NOTE 3 A 48 V vented nickel-cadmium battery consisting of 40 cells with a nominal capacity of 180 Ah is to be
rd
charged with an IUI charger having an output current of 10,0 A in the 3 charging step, corresponding to 10,0/180 =
0,056 A/Ah = 5,6 A/100 Ah. As this value is higher than 5,0 A/100Ah, the value of the current in the 3rd charging
step shall be used as I , i.e. 5,6 A/100 Ah.
gas special
The ventilation air flow requirement amounts to: Q = 0,05 × 40 × 5,6 × 180/100 = 20,2 [m /h].
6.2.4 Unconventional chargers
When a so-called "fast charger" or a charger with unconventional characteristics e. g. a “pulse
charger” is used, then the specific value for I shall be obtained from the charger
gas special
manufacturer.
6.2.5 Multiple charging
When two or more batteries are simultaneously being charged in the same room, then the
ventilation requirement shall be the sum of the individual ventilation air flow needs.
6.3 Natural ventilation
The amount of ventilation air flow shall preferably be ensured by natural ventilation, otherwise
forced (artificial) ventilation shall be implemented.
Charging rooms and charging areas require, under natural ventilation conditions, an air inlet
and an air outlet with a minimum free area of opening calculated by the following formula:
A = 28 × Q
where
Q is the ventilation flow rate of fresh air [m /h];
A is the free area of opening in air inlet and outlet [cm ].
NOTE For the purpose of this calculation the air velocity is assumed to be 0,1 m/s.
The air inlet and outlet shall be located at the best possible location to create best conditions
for exchange of air, i.e. with
− openings on opposite walls;
− minimum separation distance of 2 m when openings on the same wall.
In open air, in large halls and in well ventilated rooms an air velocity of ≥ 0,1 m/s can be
assumed and an adequate air ventilation is ensured.
Well ventilated rooms shall have a free volume of at least 2,5 × Q [m ] .
The air inlet and outlet shall be in the best possible location for the exchange of air, i.e.
– openings on opposite walls,
– minimum distance apart of 2 m when openings are in the same wall.
The air extracted from the charging area/room shall be exhausted to the atmosphere outside
the building.
62485-3 © IEC:2010 – 15 –
6.4 Forced ventilation
Where an adequate air flow Q cannot be obtained by natural ventilation and forced ventilation
is implemented, the charger shall be interlocked with the ventilation system or an alarm shall
be actuated when the required air flow, for the selected mode of charging, is not assured.
The air extracted from the charging room shall be exhausted to the atmosphere outside the
building.
6.5 Close vicinity to the battery
In the close vicinity of the battery, the dilution of explosive gases is not always secured.
Therefore, a safety distance of minimum 0,5 m extending through the air without flames,
sparks, arcs or glowing devices (maximum surface temperature 300 °C) shall be observed.
6.6 Ventilation of battery compartment
6.6.1 Where removable covers are provided for the battery and when appropriate, the covers
shall be removed prior to charging in order to ventilate gas produced and aid battery cooling.
6.6.2 Suitable ventilation openings shall be provided in the battery container, compartment or
cover so that during discharge or rest periods, dangerous accumulation of gas does not occur
when the equipment is used in accordance with the manufacturer's instructions.
The ventilation opening area shall be at least:
A = 0,005 × n × C [cm ]
where
A is the total cross-sectional area of ventilation holes required [ cm ] ;
n is the number of cells in battery;
C is the capacity of battery at the 5 h rate [Ah].
7 Provisions against electrolyte hazard
7.1 Electrolyte and water
Electrolyte used in lead-acid batteries is an aqueous solution of sulphuric acid. Electrolyte used
in NiCd and NiMH batteries is an aqueous solution of potassium hydroxide. Distilled or
demineralised water is used when topping up the cells.
7.2 Protective clothing
In order to avoid personal injury from electrolyte splashes when handling electrolyte and/or
vented cells or batteries, protective clothing shall be worn, such as
− protective glasses or face shields,
− protective gloves and aprons.
In the case of valve-regulated or gastight sealed batteries, at least protective glasses and
gloves shall be worn.
7.3 Accidental contact, "first aid"
7.3.1 General
Acid and alkaline electrolytes create burns in eyes and on the skin.
– 16 – 62485-3 © IEC:2010
A source of clean water, from tap or a dedicated sterile reservoir, shall be provided in the
vicinity of the battery under charging or maintenance for removing electrolyte splashed onto
body parts.
7.3.2 Eye contact
In the event of accidental contact with electrolyte, the eyes shall be immediately flooded with
large quantities of water for an extended period of time. In all cases immediate medical
attention shall be obtained.
7.3.3 Skin contact
In the event of accidental skin contact with electrolyte, the affected parts shall be washed with
large quantities of water or with adequate neutralising solu
...
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